Building construction



April 17, 1934 D. E. Ross Er AL.

BUILDING CONSTRUCTION Filed July 18, 1932 4 Sheets-Sheet l m'an April 17, 1934. D. E. Ross Er AL 1,954,891

BUILDING CONSTRUCTION Apnl 17, 1934. D, E R055 Er AL 1,954,891

BUILDING CONSTRUCTION Filed July 1s, 1952 4 sheeis-sheet 3 rl lllllflllll Il April 17, 1934. D. E. Ross Er A1.

BUILDING CONSTRUCTION Filed July 18, 1932 4 Sheets-S1166?. 4 19g 23 Patented pr. 17, 1934 NT) STATES BUILDING CONSTRUCTION David E. Ross and Floyd P. Wymer, La Fayette, Ind., assignors to Rostone, Incorporated, La Fayette, Ind., a corporation of Indiana Application July 18, v193.2, Serial No. 623,268

24 Claims.

Our invention relates to an improvement in the construction of buildings and its object is to provide a simplified reproof building construction.

In our invention we employ sheet metal forms which can be filled with concrete forming studs which take the A'place of the ordinary studding; the forms can be easily and quickly erected and assembled by unskilled labor and will result in a great saving in the cost of construction. We also provide novel means for supporting flooring; and novel means for attaching outer and inner walls to the studding. `Other novel features of the invention and novel details of construction will be hereinafter pointed out.

In the accompanying drawings we have illustrated studding forms such as required for various portions of a building, means for mounting the flooring on the studs and means for attaching inner and outer wall blocks to the studding to form the complete wall and an understanding thereof will enable others to construct buildings from such material. In the appended claims we have summarized the essentials of the invention and novel features of construction and novel combinations of parts for which protection is desired.

In the drawings:--

Fig. 1 is a transverse section through one of the novel studs in a straight run of the wall.

Fig. 2 is a detail front View partly in section of the stud shown in Fig. 1 with the walls removed.

Fig. 3 is avtransverse section through the stud and wall showing the support for a oor beam.

Fig. 4 is a vertical section on the line 4 4, Fig. 3.

Fig. 5 is an inner face view partly in section of a complete stud.

Fig. 6 is a detail section on the line 6 6, Fig. 3.

Fig. '7 is a sectional view illustrating the connection of a partition wall with the main wall.

Fig. 8 is a sectional View illustrating the stud for the partition wall.

Fig. 9 is a sectional View illustrating studding for a corner of a building.

Fig. 10 is a sectional view illustrating a studding for an intersection of walls.

Figs. 1l and 12 are detail views of a device for fastening the wall blocks to the studding.

Fig. 13 is an inside face view of a wall block of preferred construction.

Fig. 14.- is a transverse section of the block on line 14-14, Fig. 13.

Fig. 15 is a transverse section on line 15--15, Fig. 13.

Fig. 16 is an inside face View of a corner block.

Fig. 17 is a side View partly in section of the corner block.

Fig. 18 is a transverse section on line lil-18, Fig. 16. Y

Figs. 19 and 20 are detail sectional views of one form of block fastening device for anchoring the outside wall blocks to the pilaster.

Figs. 21 and 22 are sectional top and side views of a form of block fastening device for fastening the blocks to the sheet metal studding.

Fig. 23 is an enlarged transverse sectional View of a stud and part of wall showing the preferred 70. form of block fastening and anchoring device.

Fig. 24 is a detail sectional View of a block showing the preferred anchoring device.

The simplest form of stud is shown in Figs.

1 to 6 and is intended to be used in a straight 75 run of wall. This stud is composed of oppositely faced U-channel members l of sheet metal bent so that the anges of the channel are sprung slightly outward from a right angle position. Between and connecting the channel 1 is a lighter sheet metal container member 2, the side ange of which may be rigidly connected to the channels 1 by some suitable means, such as welding. Placed within the container 2 is a transverse brace 3 of heavier metal. A full length section of stud for a single door is shown in Fig. 5, Abrace members 3 being placed at spaced intervals apart throughout the length of this stud. Fig. 5 illustrates the distribution of the braces, beam supports, and slots. Short lengths of angle 5 may be fastened by some suitable means such as weldingv to thebottom of the stud and by means of these the stud can be fastened to the foundation. As shown the flanges of the side channels 1 are provided with spaced slots 1a for engagement of the wall block attaching devices hereinafter explained.

The members 1 and 2 when erected act as sheet metal forms, bounded on three sides by part 2 and on the fourth side by the outside wall 20, and 100 are to be filled with a building material giving -the required anchorage, such as concrete, masonry or the like--thus forming a solid stud or pilaster, which may be reinforced if desired. In the case of the inside wall, there is an air space between the sheet metal form and the interior insulating wall board completely around the building. In Figs. 1, 3 and 7-10 the area to be lled with concrete or similar material in the Various forms of studs is lled as indicated at F.

It is intended that the outside Wall will be positioned before the forms are filled.

Outer wall blocks 20 are shown in Fig. 1 as provided with fastening members 20a which may be hinged to the inner face of the blocks and can be extended at right angles thereto. These members 20a may be entered through the openings 1a (Fig. 2) inthe iianges and a fastening wedge 20D dropped through the hole in the member 20a to secure the blocks in place as hereinafter described. (See Figs. 11, 12 and 21, 22.) Inner wall blocks 40 may be similarly secured to the other flange by means of similar fastening members 20a. The application of these wall blocks 20 and 40 will be more fully described later.

Between the wall blocks 20 and 40 and the flanges of members 1 may be placed sheets 20x and 40m of an insulating material such as wall board. When the blocks are fastened to the studs, the sprung ends of the flanges of members 1 will bite or dig into the wall board, takingup all play as well as permitting a certain resiliency,

.so that it is impossible to pull the fastening device from the block.

A support 4 for a ceiling or floor beam B, can be located at any desired height in the stud, see Figs. 3 to 6. To facilitate the placing of the floor beams a rectangular hole is cut in part 2 on the side adjacent to the inside wall. It is apparent that when the stud is filled, the area of this hole not taken up by the beam will have to be covered to prevent the filler from running out. A piece of light gauge metal 4x having a hole cut therein the shape of the cross section of the beam,

is placed on the beam adjacent the sheet metal member 2, during erection, as shown in Figs. 3 and 4. Reinforcing rods 41 are arranged in the stud and extend each side of the floor beam B, passing through the holes shown in part 4, Fig. 3, and coincident holes in the beam, thus producing a rigid connection between the beam and the stud.

To suit requirements of buildings various forms of stud are required, see Figs. 7 to 10. Fig. 8 illustrates a stud for a partition wall. In this case parts 1 are the same, but part 2 has its ends inturned as at 2b and a plate 2e is placed therebetween to make'an enclosed rectangular form. Part 3 is the same as in Fig. 1. In this case concrete or filler does not come in contact with the wall blocks but is bounded on all four sides by the metal form. K-Fig. '7 illustrates a stud for the connection of a partition wall with the main wall. In this figure, parts l are the same as before described but part 2 has a'projecting bend 2a adapted to extend somewhat into the partition Wall and a third U-member 1x is attached to this bend to engage the partition wall members as shown. This stud is stiffened by a triangular brace 3d and by transverse ties 3e as shown in Fig. 7.

Fig. 9 illustrates the studding for a corner of a building. Parts 1 are the same but the shape of part 2 is changed as indicated at 2c. The members 1 are disposed at right angles to each other and are connected by a member 2c which is shown as bent into approximately W-shape.

so that it can turn the corner. The Vmember 2c is stiffened by a diagonal brace 3a fastened at the ends and middle to part 2c. This makes a rigid triangular construction which holds the corner stud form in shape, and this form is further braced by rods or bars 3f, located at intervals determinedY by the height of the wall slabs, and to bars 3f the corner blocks 3G are fastened.

Fig. 10 illustrates the stud for an intersection of walls where the outside wall turns in the manner shown in the upper left hand corner of the ligure, which is the case when a wing is built onto a rectangular house, and partition Walls go olf towards the interior of the house. In this case the members 1 are constructed as above described but four are used and the member 2 is replaced by a member which is approximately bent into cruciform shape so that it has an angular member 2d projecting into the space between each of the four Walls and a member 1 being connected to each of the four projections 2d. The member 2d is interiorly braced by L-shaped bars 3b and straight bars 3c as shown in Fig. 10.

After the stud members are erected the exterior Walls may be secured thereto. The exterior Walls are made of blocks or slabs. These blocks may be made of concrete, but are preferably of Rostone. However, this stud design is not limited to molded stone blocks, but can be used in conjunction with practically any current building practice.

In Figs. 13 to 18 we have indicated generally the preferred form of block and the device for fastening the same as shown in Fig. 13. The blocks 20 for the outside wall are designed With a lap on all four edges to facilitate weather proof construction. A coating C of resinous material (Fig. 19) is preferably placed on the meeting edges of the blocks which acts as a buffer between the blocks, and also to seal the joint. This resinous or plastic material can be put in a fabric such as lamp wick, so as to insure its adhesion and uniformity of thickness.

The blocks 20 for the outside Wall preferably have a reinforcing wire mesh as 21 molded therein. A series of shallow, vertical grooves 25 may be formed on the inside faces of the blocks in the areas that come in contact with the stud; these grooves tend to make a more rigid construction by providing more irregular surface contact with the f lller. l

For the corners, blocks 30 (see Figs. 16-18) are used. `One end of the block 30 may be provided with dowel pins 30e (see Fig. 9) to hold it in place with the adjacent block 20 v(see Fig. 9). The other end of this block can be held in place by stud bolts 30d which engage nuts 30h embedded in the block (see Figs. 9, 16, 18), the bolts .30d engaging the member 3f to fasten the corner blocks to the stud, see Fig. 9.

Figs. 11, 12,21 and 22; show fastening devices in the blocks. As shown in Figs. 1l, 12;

and 21, 22 the fastening devices comprise a lug y f 22 which is hinged in a recess of the block 40 to the reinforcing wire and for transport lies `Concealed in the recess as indicated in dotted lines in Fig. 13. This lug is adapted to be turned out at right angles to the block and can be entered i in the slots la in the channel 1 and secured by means of a wedge 23 inserted through an opening in the lug. These fastening devices all show more clearly in Figs. 21 and 22.

When the block is manufactured this lug lies i. au

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ably formed by having the end or ends 21e'. of the reinforcingv mesh 21 bentv so as to appear-on the surface of the block` and extend along flush with the surface for a short distance within that area of the block opposite the stud as shown in Fig. 23. The anchor members 21o remain in this position until the block is ready to be placed in the wall, then these wires are bent to a position perpendicular to the face of the block. When the blocks are attached to the stud by lugs 22 these members 21e project into the stud mold formed by the members 1, 2 and walls, and when the stud is lled with concrete, or other suitable filler, the members 21e are permanently anchored in the concrete and thus lock the outer wall blocks to the studs to form a very rigid wall construction.

Figs. 19 and 20 show another means for anchoring the blocks to the studs. In this case l.- shaped anchors 22a are hinged to the ends of the block. These lie flushwith the block surface until used, thenthey are pried out and extend into the stud and are anchored in the concrete when the form is filled--thus securing theblock permanently to the stud and making the structure very rigid. These L-shaped anchors 21o or 22a are intended to extend into the space left for the pilaster and become an integral part of the pilaster when the form is filled, thus locking the blocks of the outer wall permanently to the pilasters; and it is very apparent that such construction would tend to make a very rigid wall, as any strain on the wall would throw an innumerable number of these rods into shear. However, it is also apparent that there must be some means of fastening the block to the metal form before the pilaster is poured, thus necessitating the use of a fastening device such as illustrated in lug 22.

The blocks could be made according to the requirement of the wall and distance apart of the studs. The blocks herein illustrated will enable anyone skilled in the art to make suitable blocks of proper size and dimensions.

By this invention we have provided sheet metal forms containing channels 1 fastened by some suitable means such as welding to containers 2 to make metal forms for the studs and which forms are left in place in the building. Conductivity of heat and cold is reduced throughout by the air spaces, which prevent direct transmission of heat and cold from the outer wall to the inner wall. These air spaces may be filled with an insulating material such as rock wool or the like in order to break up any currents of convection which might occur in a large air space.

The construction shown provides multiple layers of wall material, the outside and inside layers 20 and 40 being the iinish; and interior layers 20a: and 40a' being non-conductive of heat or cold. The lack of conductivity is also enhanced by the dead air spaces and insulating filling. This construction not only aids in eliminating transmission of heat and cold but also aids in excluding outside noises and renders the interior of the building very quiet. The spaces between studs can be used advantageously for placing windows.

This construction provides a very rigid structure with a very small amount of metal tonnage and a very small amount of concrete or binding material is required in the studs. It provides novel and rapid means for securing the outside and finishing blocks or walls yto the studs. The corrugations in the ends of the blocks adjacent the stud make very rigid, non-weaving joints. The elimination of mortared joints and the use of a cushioning material at the joints lessens danger of chipping the edges of the blocks, eliminates labornecessary for mortar joints, and at the same time secures a perfect weather seal.

The spaces between adjacent studs can be utilized for utilities such as hot air ducts, water pipes, steam pipes, electric wires, air conditioning in the house, etc. and inside slabs can be made removable for the inspection of the various utilities where desired.

1. In a building, a stud comprising metal members having flanges for engagement with the walls; and a metal container member interposed between the ilrst said members and connected thereto and forming 'therewith a mold for a concrete ller; and wall blocks having anchoring members on their ends adapted to project into the stud mold and be embedded in the concrete ller.

2. In a building, a stud comprising metal members having flanges for engagement with and attachment to the walls, a metal container member interposed between the iirst said members and connected. thereto, and wall blocks having fasteners engaging the channel members and forming therewith a mold for a concrete ller; said wall blocks having anchoring members on their ende projecting into the stud and embedded in the concrete filler.

3. In a building; a stud comprising metal members having anges for engagement with and attachment to the walls; a metal container member interposed between the first said members and connected thereto, said stud having openings in .i

flanges adapted to extend parallel with the walls of a building; a bent metal container member interposed between the rst said members and connected thereto; and a filling material within said container member.

5. A stud as set forth in claim 4, having a fioor beam support arranged transversely of and within the container member.

6. A stud as set forth in claim 4, having a :door beam support secured transversely of and within the metal container member, and reinforcing rods extending through said support and embedded in said filler.

'7. A stud as set forth in claim 4, having openings in the outwardly projecting flanges of the said blocks having anchoring channel members for engagement with fastening members to secure the walls to the stud.

8. A stud as set forth in claim 4, having openings in the anges of the channel members, and wall members having fasteners projecting therefrom and entered through the openings in the channel members.

9. A stud for buildings as set forth in claim 4, having transversely disposed braces within the container and connected therewith.

`10. A stud for buildings, comprising oppositely facing spaced metal channel members having flanges for engagement with and attachment to the outer and inner walls of the building, a metal container member interposed between the said channel members and connected thereto and forming therewith a mold, spaced transversely disposed braces within the container and connected therewith, and a concrete filler in said mold.

11. In a building, studs comprising oppositely facing spaced channel members having flanges extending parallel with the walls, a metal container member interposed between the said channel members and connected therewith, and wall members secured to the flanges of the channel members.

12. In a building, studs comprising opposite spaced channel members having anges for engagement with and attachment of wall members of the building and extending parallel with the walls, a metal container member interposed between the said channel members forming a mold for concrete or other plastic ller, transversely disposed braces Within the container, and wall members attached to the flanges of the channel members.

13. A stud for buildings, comprising spaced oppositely facing channel members having their flanges extending outwardly parallel with the walls of the building, a metal container member interposed between the said channel members and connected therewith to form a mold, transversely disposed braces within the container, a floor beam support secured transversely of and within the metal container member, and reinforcing rods extending through said support.

14. A partition wall stud comprising spaced metal channel members having outwardly extending flanges, a metal container member interposed between the said channel members and having flanges on its ends, and a metal sheet interposed between the container fianges to close the open side of the container.

l5. A stud as set forth in claim 14 having transversely disposed braces within the container.

16. A stud for a partition wall connection; comprising oppcsitely facing spaced channel members having flanges, a metal container member interposed between the said channel members and having a rectangular projection intermediate the side adjacent the partition wall, and a third channel member attached to said projection.

17. A stud as set forth in claim 16 having transversely disposed braces within the container.

18. A corner stud comprising a plurality of spaced channel members having anges for attachment of the walls of the building, and a metal container member interposed between the said channel members and connected therewith, said container member being bent into approximately W-shape and the channel members being disposed Vat approximately right angles to each other.

19. A stud as set forth in claim 18 having brace bars connected with the channel member and projecting at the opposite side thereof for the attachment of corner blocks.

20. A stud as set forth in claim 18 having a diagonal brace connecting the ends of the container member.

2l. In combination with a corner stud as set forth in claim 18, outer wall blocks secured to the channel members and disposed at right angles to each other, and a corner block interposed between the adjacent ends of said wall blocks and attached to the said bar.

22. An intersection stud comprising a metal container member bent into approximately cruciform shape, and flanged channel members, one channel member being attached to each projection of the container member with its flanges outermost.

23. An intersection stud comprising a metal container member having four spaced bends adapted to project into intersecting walls, a channel member attached to each projection of the container member and having outwardlyprojecting anges, and braces within the container member connecting diametrically opposite bends thereof.

24. A building having studs, each comprising spaced flanged metal members and a container member assembled to form a mold for a concrete ller; and wall blocks having anchoring inembers on their ends projecting into the studs and embedded in the concrete llers and abutting said l.

flanges.

DAVID E. ROSS. FLOYD P. WYMER. 

